mazda 323 16v i b6

Adjustment Data

MAZDA - 323 - 1.6i - B6

Engine (general)

Item UnitsValues

Engine code B6

Capacity (cc)1598

Idle speed (rpm)850 ± 50

Valve clearance

Hydraulic

Compression pressure

Normal (bar)13.5

Minimum (bar)9.5

Oil pressure (bar / rpm)1.95 - 2.94/1000

Fuel system (make & type) EGI

Adjustment screws (A = idle speed B = CO) A

Firing order 1-3-4-2

2 ± 1/850Timing stroboscopic (before TDC) (° / rpm)

Vacuum advance

Start (° / mmHg)0 ± 3/75

End (° / mmHg)26 - 30/450

Centrifugal advance

Start (° / rpm)0 ± 2/1200

End 17 ± 2/3500 (° / rpm)

Ignition-coil resistance, primary (ohms)1.04 - 1.27

Ignition-coil resistance, secondary (ohms)6000 - 30000

NGK/BPR5ES11 Spark plugs (make & type) Bosch FR7DCX

Spark-plug gap 1.0 - 1.1 (mm)

Fuel-pump pressure (bar)2.7 - 3.2

CO exhaust gas (%)< 0.5

CO2 > 14 (%)

HC (ppm)100

O2 (%)0.3 ± 0.2

Lambda 0.98-1.03

Lambda change (Delta Lambda) 0.03

Oil temperature during test 60 (°C)

Fast-idle speed (rpm)2500-2800

CO at fast-idle speed (%)< 0.3

Cooling system

Item UnitsValues

Cap pressure (bar)0.75 - 1.05

Thermostat opens at (°C)82

Fan on at 97 (°C)

Electrical

Item Values Units

Battery (Ah)50

Alternator 65 (A)

Brakes

Item UnitsValues

Disc thickness, front, min. (mm)16.0

Drum diameter, rear, max. (mm)201

Steering and wheel alignment

Item UnitsValues

Toe-in, front (°)12' ± 18'

Camber, front (°)-5' ± 45'

Castor, front (°)2° 05' ± 45'

K.P.I., front (°)12° 25'

Toe-in, rear (°)12' ± 18'

Camber, rear (°)-20' ± 45'

Wheels and tyres

Item UnitsValues

Tyre size 155/80R13

Optional 175/70R13

Front tyre pressure 2.0 (bar)

Rear tyre pressure (bar)1.8

Capacities

Item UnitsValues

Engine sump, incl. filter (l)3.4

Manual transmission

Gearbox refill (l)2.68

Cooling system (l)5.0

Torque settings

Item UnitsValues

Cylinder head

Stage 1 20-30 (Nm)

Stage 2 (Nm)40-60

Stage 3 (Nm)76-81

Front hub 157 - 235 (Nm)

Wheel nuts (Nm)90 - 120

Spark plugs (Nm)15 - 23

© Copyright, Wessels + Mьller AG

Environmental Data

MAZDA - 323 - 1.6i - B6

Item UnitsValues

Engine code B6

Idle speed (rpm)850 ± 50

Fuel system (make & type) EGI

Adjustment screws (A = idle speed B = CO) A

Timing stroboscopic (before TDC) 2 ± 1/850 (° / rpm)

Vacuum advance

Start (° / mmHg)0 ± 3/75

End (° / mmHg)26 - 30/450

Centrifugal advance

Start (° / rpm)0 ± 2/1200

End (° / rpm)17 ± 2/3500

Fuel-pump pressure (bar)2.7 - 3.2

CO exhaust gas (%)< 0.5

CO2 (%)> 14

HC (ppm)100

O2 (%)0.3 ± 0.2

Lambda 0.98-1.03

Lambda change (Delta Lambda) 0.03

Oil temperature during test (°C)60

Fast-idle speed 2500-2800 (rpm)

< 0.3CO at fast-idle speed (%)


Error codes

Diagnostic plug

Diagnostic plug: 1 = Datalink LED tester (FEN) 3 = activation error codes (TEN) 4 = positive battery terminal (+B) 5 = ground

Read-out

-Connect LED tester to positive battery terminal and diagnostic-plug terminal 1. -Connect diagnostic-plug terminal 3 to ground. -Turn ignition on. -Error codes will appear on LED tester.

Reset

-Turn ignition off. -Disconnect negative terminal of the battery. -Depress brake pedal for at least 5 seconds. -Connect negative terminal of the battery. -Verify that no error codes are displayed.

Signal

-Digit 1 (tens position): Light pulse 1.2 seconds long, 0.4 seconds pause in-between. -Pause 1.6 seconds light-off. -Digit 2 (units position): Light pulse 0.4 seconds long, 0.4 seconds pause in-between. -Pause 4.0 seconds light-off.

Error codes

02 Hall sensor, no signal (SGT). 03 Hall sensor, no signal (SGC, DOHC engines). 08 Airflow meter, open or short circuit. 09 Coolant temperature sensor, open or short circuit. 10 Air temperature sensor, open or short circuit. 12 Idle and throttle wide open switch open or short circuit. 14 Absolute pressure sensor (inside ECU), open or short circuit. 15 Oxygen sensor, lean signal for longer than 86 seconds, engine speed is higher than 1500 rpm, warm engine. 17 Oxygen sensor signal does not change for 30 seconds, engine speed is higher than 1500 rpm. 26 Canister purge solenoid, open or short circuit. 34 Idle speed control valve (ISC) open or short circuit.

WorkshopCD© Electude NL, The Netherlands

30. airflow meter

Function

The airflow meter uses an air temperature sensor and a movable vane connected to a potentiometer, which return a signal to the control unit, proportional to the temperature and volume of air entering the engine. When air enters the engine, the airflow meter closes the fuel-pump contact, activating the fuel pump.

Specifications

supply voltage: 5 V output voltage: 0 - 5 V resistance air temperature sensor: 2,000 - 3,000 ohms / 20°C waveform information: output signal during acceleration

Scope image 1

Pins to ground: 2O


2. canister purge solenoid

Extra Info

Function

The evaporative canister is equipped with a purge solenoid valve. The control unit switches the solenoid on or off. This controls the amount of vapour purged into the inlet manifold.

Specifications

supply voltage: 12 V resistance: 25 - 35 ohms

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check resistance: Turn ignition off. Remove connector from solenoid. Measure resistance between the two pins of the solenoid. Compare with specified resistance. Alternatively, check solenoid function by applying battery voltage to its pins. The solenoid should "click". Check supply voltage: Turn ignition off. Remove connector from solenoid. Start the engine and measure voltage between one connector terminal and the negative terminal of the battery. Checkthe second terminal. One of the two should equal battery voltage. If not check wiring and, if present, fuse(s) and relay.

Check connection to ECU: Turn ignition off. Remove connector from solenoid and ECU. Measure the resistance between one of the two connector terminals and the corresponding terminal in the ECU connector. Check the other terminal. One of the two should be < 1 ohm. If not check wiring.


CANISTER PURGE SOLENOIDFunction

The evaporative gases produced in the fuel tank are absorbed by the activated charcoal in the carbon canister. As The purge control solenoid valve opens these gases are delivered to the intake manifold for combustion purposes. The purge control solenoid valve is controlled by the control unit. The control unit operates this valve during the time the lambda control loop is active.

Specifications

RESISTANCE:

± 50 ohmsresistance:

12 Voltssupply voltage:

current: ± 250 mA

Electrical control

Most solenoids are normally closed. This means that the connection between the canister and the intake manifold is closed. The solenoid has a connector with two terminals. On one of those terminals is connected to the battery voltage. This supply-voltage is often switched with a relay. The other terminal leads directly to the control unit. The current through the solenoid is switched on during the time the control unit connects this terminal to ground. The voltage on this terminal is during this time 0 Volts. During the time the solenoid is switched off, the voltage on this terminal is 12 Volts. Some motormanagement systems control the amount gases delivered to the intake manifold switching the solenoid on and of with a certain duty cycle. In this case the duty-cycle depends on engine RPM and engine load.

Electrical diagnosis

STATIC

General

To perform this measurements the relay switching the power to the solenoidshould be closed. Short circuit the switch in the relay if necessary.

Measurements

Measure the voltage on the control unit. Use the pin which switches the solenoid.

12 Vresult:

solenoid and wiring are electrically OK

0 V

check the relay switching the power to the solenoidcheck the wiring between the relay and the solenoidcheck the solenoid resistancecheck the wiring between the solenoid and the control unitcheck the control unit

100. control unit

Function

The control unit receives signals from sensors that monitor various engine operating parameters. The control unit generates output signals to provide optimal air/fuel ratio, idle speed control and ignition timing.

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. When you suspect the control unit is faulty, make sure all sensors and actuators function properly, and that signals from other control unit(s) are received properly. Next check the supply voltage and ground connections of the control unit: Turn ignition off. Remove ECU connector. Locate the supply voltage connections. Turn ignition on. Measure voltage between corresponding connector terminal(s) and the negative terminal of the battery. They should equal battery voltage. If not check wiring and fuse. Turn ignition off. Locate the ground connections. Measure resistance between corresponding connector terminal(s) and the negative terminal of the battery. They should be < 1 ohm.


42. coolant temperature sensor

Function

The coolant temperature sensor is a temperature-sensitive resistor. Low temperature causes high resistance while high temperature causes low resistance. The control unit determines the temperature by monitoring the voltage across the sensor.

Specifications

supply voltage: 5 V (connector disconnected) resistance: 2,000 - 3,000 ohms / 20°C resistance: 200 - 300 ohms / 90°C

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check resistance: Turn ignition off. Remove connector from sensor. Measure resistance between both pins of the sensor. Compare with specified resistance. Check supply voltage: Turn ignition off. Remove connector from sensor. Turn ignition on and measure voltage between both connector terminals and the negative terminal of the battery. One should be 5 V. If not check wiring then check ECU. Check connection to ECU: Turn ignition off. Remove connectors from sensor and ECU. Measure the resistance between supply voltage connector terminal and the corresponding terminal in the ECU connector. It should be < 1 ohm. If not check wiring. Check ground: Check in schematic if ground connection is connected to a direct ground or to the ECU. When it is connected directly to ground: Turn ignition off. Remove connector from sensor and measure resistance between ground connector terminal and the negative terminal of the battery. It should be < 1 ohm. If not check wiring. When it is connected to theECU: Turn ignition off. Remove connector from sensor and ECU. Measure resistance between ground connector terminal and the corresponding terminal in the ECU connector. It should be < 1 ohm. If not check wiring.


83. diagnostic connector

Function

This connector is used to communicate with the control unit.

Specifications

For more information on reading error codes click the error codes button on the toolbar.


3. fuel pumpExtra Info

Function

The fuel pump consists of an impeller driven by a DC motor. The fuel pump and the fuel pressure regulator maintain constant pressure at the injectors.

Specifications

supply voltage: 12 V maximum pump pressure: 4.5 - 6.0 bar system pressure (vacuum connected): 2.1 - 2.6 bar


FUEL PUMPFunction

The fuel pump is an electrically operated pump which lifts the fuel from the fuel tank and pumps it under pressure through a filter to the fuel rail or throttle body. The fuel runs along theinjector(s) and returns to the tank via the fuel pressure regulator. Some systems use two pumps. The fuel lift pump inside the tank and the fuel pressure pump outside the tank.

Specifications

pump pressure: ± 0,25 - 6 bars

± 0,6 - 1,1 bar (single-point)system pressure:

± 2 - 3,5 bar (multi-point)

flow: ± 50 - 100 l/h

supply voltage: 12 Volts

current: ± 5A

Electrical control

The fuel pump is operated by a relay. The conditions the relay is closed are.

during several seconds after switching on the ignitionduring the time the system receives RPMpulses.

The fuel pump relay is often controlled by the control unit.

The relay coil has two terminals. On one of those terminals is connected with the battery voltage. The other terminal leads directly to the control unit.

The current through the relay coil is switched on during the time the control unit connects this pin to ground. The voltage on this pin is during this time 0 Volts. During the time the relay is not switched on, the voltage on the pin is 12 Volts.


STATIC

General

Turn the ignition switch "on"Listen to the fuel pump operating sound. The fuel pump should operate for several seconds after the ignition switch is turned "on"

Power supply

To perform this measurements the relay switching the power to the fuel-pump should be closed. Short circuit the switch in the relay if necessary.

Measurements

Disconnect the fuel pump connector. Measure the voltage over the fuel pump terminals in the connector. The voltage should be 12 Volts.

result: 12 V

replace the fuel pump

0 V

check ground circuitcheck the wiring between the relay and the pumpcheck the relay switching the power to the pump

diagnosisMechanical

Measurements

To perform this measurements the relay switching the power to the fuel-pump should be closed. Short circuit the switch in the relay if necessary.check the fuel system pressure

check the fuel level in the tankresult:check the fuel pressure regulatorcheck the fuel filterscheck the fuel pumpcheck the fuel return circuit to the tank

91. fuel pump relay

Function

The fuel pump relay switches power to the fuel pump.

Specifications

single normally opened relay with two coils.


40. Hall / MRE sensor on camshaft

Function

The shutter blades mounted on the rotor pass through the Hall sensor, which detects the change in magnetic field and sends a signal to the control unit.

Specifications

supply voltage: 12 V waveform information: engine running at idle waveform A: terminal 2E waveform B: terminal 2G

Scope image 1

Pins to ground: 2E, 2G


36. idle and throttle wide open switch

Function

The idle switch is closed when the throttle is fully closed. The throttle wide open switch is closed when the throttle is fully open.

Specifications

supply voltage idle switch: 12 V supply voltage throttle wide open switch: 5 V idle switch: normally closed throttle wide open switch: normally open


6. idle speed control valve

Extra Info

Function

The idle speed control valve regulates the by-pass airflow.

Specifications

supply voltage: 12 V resistance coil: 10 - 15 ohms waveform information: engine running at idle

Scope image 1

Pins to ground: 2W

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check resistance: Turn ignition off. Remove connector from valve. Measure resistance between the two pins of the valve. Compare with specified resistance. Check supply voltage: Turn ignition off. Remove connector from valve. Crank the engine and measure voltage between one connector terminal and the negative terminal of the battery. Check the second terminal. One of the two should equal battery voltage. If not check wiring and, if present, fuse(s) and relay. Check connection to ECU: Turn ignition off. Remove connector from valve and ECU. Measure the resistance between one of the two connector terminals and the corresponding terminal in the ECU connector. Check the other terminal. One of the two should be < 1 ohm. If not check wiring. Check valve activation: Connect oscilloscope to the signal pin of the ECU and ground. Start the engine and compare to the scope image shown.


IDLE SPEED CONTROL VALVEFunction

The idle control valve is located in a tube bypassing the throttle. The control unit controls this device to ensure stable idling in all operating conditions.

Specifications

resistance coil(s): ± 20 ohms

supply voltage: 12 Volts

A rotary slide valve attached to the armature is turned to open the air bypass until the desired idle speed is obtained. The position of the armature is controlled by the force of an internal spring opposing the force of a solenoid (types with to terminals) or controlled by two solenoids energised alternately which exerts opposing forces on the armature (types with three terminals).

Electrical control

Types with two terminals

As a current flows through the coil the armature is turned against the spring force. As the current increases the airflow and the idle speed increases.If the current through the coil is switched off due to a mall functioning system, the valve is forced into a position which results in a (too) high idle speed.

The idle control valve has a connector with two terminals. On one of those terminals is connected to the battery voltage. This supply-voltage is often switched with a relay. The other terminal leads directly to the control unit. The current through the coil is switched on during the time thecontrol unit connects this terminal to ground. The voltage on this terminal is during this time 0 Volts. During the time the current through the coilis switched off, the voltage on this terminal is 12 Volts.

The control unit controls the current through the coil switching the current on and off with a certainduty cycle. The current increases as the duty-cycle increases. The duty cycle varies between approx. 35% (valve closed) and 85% (valve opened). Nominal idle speed is obtained when slightly open.

Three terminal types

The two coils inside this type of idle speed controlvalve are connected with the supply voltage usingone common terminal. The other two terminals lead directly to the control unit. The control unit switches the current through the solenoid on and off alternately with a duty cycle between 35 and 85%.


DYNAMIC TESTS THREE TERMINAL TYPESSTATIC

To perform this measurements the Remove the idle control valverelay switching the power to the idle but leave the electrical control valve should be closed. connections in place. Fully Short circuit the switch in the relay open or close the rotating if necessary. plunger. Switch on the

ignition.Measurements:

Disconnect the connector and

measure the resistance of the coil(s). The nominal value is app. 20ohms.

Check the relay switching the power result: Switch on the ignition. The to the idle control valve rotating plunger must move Check the wiring between the relay to a position equivalent to and the idle control valve app. 50% opening, and

remain there.Check the wiring between the idle control valve and the control unitCheck the control unit

diagnosisMechanical

Check the air chamber on air leakage. Check engine on air leaks into the intake system.Remove the idle control valve. The plunger should rotate or move easily. Clean if necessary.

11. ignition coil

Extra Info

Function

The ignition coil stores energy when current is passed through the coil primary. When the current is switched off a high voltage is induced in the coil secondary.

Specifications

supply voltage: 12 V resistance primary coil: 0.5 - 1.5 ohms resistance secondary coil: 10,000 - 16,000 ohms waveform information: engine running at idle

Scope image 1

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check resistance primary coil: Turn ignition off. Remove connectors from ignition coil. Measure resistance between supply voltage connector pin and primary switching connector pin of the ignition coil. Compare with specified resistance. Check resistance secondary coil: Turn ignition off. Remove connectors from ignition coil. Measure resistance between central lead terminal and primary switching connector pin. Compare with specified resistance. Check supply voltage: Turn ignition off. Remove connectors from ignition coil. Turn ignition on and measure voltage between supply voltage connector terminal and the negative terminal of the battery. It should equal battery voltage. If not check wiring and, if present, fuse(s) and relay. Check connection to ignition module: Turn ignition off. Remove connector from ignition coil and ignition module. Turn ignition on and measure resistance between primary switching connector terminal and corresponding terminal in ignition module connector. It should be < 1 ohm. If not check wiring. Check ignition signal: Connect oscilloscope to the ignition module pin corresponding to the primary switching wire of the ignition coil and ground. Start the engine and compare to the scope image shown.

IGNITION COIL Function

The ignition coil transforms the battery voltage into the high voltage needed to create a spark.

The ignition coil consists of an electromagnet (the primary coil) and a high voltage coil (secondary coil).

By switching the current through the primary coil on, a magnetic field is induced. The moment the current is switched of, the magnetic field suddenly disappears.

This change of magnetic field creates an induction voltage in the secondary coil, high enough toionise the mixture. The ionised mixture is a conductor and a current flows through the spark plug.

Specifications

RESISTANCE:

primary: ± 0,3 - 2 ohms

secondary ± 5k - 20k ohms

supply voltage: 12 V

current limited at: ± 7A

Systems with a distributor

Ignition coils used in combination with a distributor consists of one primary and one secondary coil.

The high voltage, induced in the secondary coil is connected to one of the spark plugs

selected by the distributor.

Wasted spark ignition coils

The secondary coil has two ends. In a normal ignition coil one of those ends delivers the highThe other end is connected to either the positive (15) or the negative (1) terminal of the primIn a wasted spark ignition coil both ends are connected to a spark plug. Therefore both sparkwill spark at the same time.

wasted spark ignition coil on 2- cylinder 4-stroke engine a wasted spark ignition coil on a 4- cylinder 4-str

To supply the four spark plugs of an 4 cylinder engine, two ignition coils are needed. The pictbelow (left) shows an ignition coil for two spark plugs. The ignition coil in the right picture incorporates two of those. This ignition coil supplies four spark plugs.

Sequential ignition

Sequential ignition systems are distributor less ignition systems using one ignition coil percylinder.

Each ignition coil is controlled by the control unit individually.

Electrical control

A current through the primary coil induces a magnetic field. The moment the current is switched of, the magnetic field suddenly disappears. This change of magnetic field induces an induction voltage and causes a spark.

The amperage before switching the current off should be high enough to create a high change of magnetic field the moment the current is switched off.

Therefore the current through the primary coil is controlled electronically.

The ignition module is supplied with a current limited circuit. Using this in combination with a low resistance ignition coil the amperage does not depend on the battery voltage.

During the time the current is switched off, the voltage over the ignition module is 12 Volts. The moment the current is switched on, the voltage drops to 0 Volts. From this moment on the current increases until the limiting value is reached.

The oscilloscope images A and B gives you an example of the primary voltage measured on two different current limiting circuits.

By increasing the voltage over the ignition module, the voltage over the primary coil decreases. This causes a limited current in oscilloscope image A.

The ignition module in oscilloscope image B switches the current on and off to limit the current.


STATIC DYNAMIC

Start the engine and measure To perform this measurements the ignition should be switched on. the primary voltage using an

oscilloscope.Measurements:

Measure the primary and secondary resistance of the ignition coil.Measure the voltage on the positive terminal of the ignition module.

The voltage should be equal to the battery voltage.

result: result: 0 VVoltage is lower than battery voltage.

check power supply.disconnect positive terminal andrepeat measurement 12 V

Voltage is equal to battery result:check ignition modulevoltage.

check primary resistance of the ignition coilcheck ignition modulecheck wiring between ignition module and ignition module.

Voltage is still lower than battery resultvoltage.

check ignition lockcheck wiring between ignition lock and ignition coil

diagnosisMechanical

!Not available for this subject

10. ignition module

Extra Info

Function

The ignition module receives its input signal(s) from the control unit and switches the current through the coil primary circuit on and off.

Specifications

supply voltage: 12 V waveform information: engine running at idle

Scope image 1

Pins to ground: 1G


IGNITION MODULE Function

The ignition module switches the current through the primary ignition coil on and off. The ignition module charges the ignition coil during the time the current is switched on. The moment the ignition module switches the current 'off' the ignition coil induces an induction voltage which causes the spark.

An ignition module switches the current on and off according to an input signal. This input is delivered by the control unit. On older systems the input signal is delivered by an inductive, Hall or opto-coupled sensor mounted in the distributor.

Specifications

- resistance

- supply voltage

Electrical control

The connector of the ignition module has several terminals. The following terminals are used on common ignition modules.

a terminal connected with the ignition coil.By this terminal the current through the ignition coil is switched on and of.a terminal connected with the supply voltage ( 12 Volts)a terminal connected with ground.terminal(s) to receive the input signal. If the input signal is delivered by an inductive sensor two terminals are needed.

The output voltage of an inductive sensor is delivered by an internal coil. This coil induces an almost sine wave output voltage. If the inputsignal is delivered by an Hall-sensor or opto-coupler three terminals are needed. Two of those three terminals are used to supply the sensor. The supply voltage is either 5 or 12 Volts. The third terminal receives the output signal from the sensor. The output voltage of these sensors is a square wave signal.

Addition terminals are possible. For example to send out a RPM signal to the revolution counter.Sometimes the input signal is delivered by a sensor while the ignition timing is controlled by the control unit. In this case the received input signal from the sensor is converted into a square wave signal by the ignition module and send out to the control unit. The control unit receiving this signal computes this input information and other input information from various engine parameters and sends out a newsquare wave signal to the ignition module. This signal is used by the ignition module to switch the current through the primary ignition coil on and off.

During the time the input signal for the ignition module is 'high' the current is switched 'on'. Themoments this input signals falls to 'low' the current is switched 'off'. This moment the sparkwill appear


Start the engine and measure (using an oscilloscope) the input signal delivered by the control unit or input sensor. The square wave signal or sine wave signal from a inductive sensor should be visible.

signal Disconnect the ignition module's connector and check the wiring between not OK: the ignition module and the control unit or input sensor.

replace the ignition module if the signal appears on the disconnected connector and disappears on the connected connector.

If the output signal remains invisible the failure is not in the component.

signal check the power supply of the ignition module.OK: check the primary voltage using an ignition oscilloscope or normal

oscilloscope with a suitable probe.check the wiring between the ignition module and the ignition coil.

The voltage should be nearly 0 Volt during the period the ignition module receives an 'high' input voltage from the sensor or control unit.

diagnosisMechanical

Remove the auxiliary air valve without disconnecting the connector.Turn the ignition on and make sure that the valve closes as the heating element heats-up the bi-metallic strip.

167. increased fuel pressure solenoid

Function

The vacuum solenoid (P.R.C.) regulates the connection between the fuel pressure regulator and the inlet manifold vacuum. The vacuum solenoid is activated by the control unit at air temperatures above 20°C, at engine speeds below 1500 rpm, and with the idle switch closed.

Specifications

supply voltage: 12 V resistance: 35 - 45 ohms


1. injector

Extra Info

Function

A fuel injector is an electrically operated solenoid valve which is powered by the control unit. The fuel injector injects fuel into the inlet manifold.

Specifications

supply voltage: 12 V resistance: 13 - 17 ohms waveform information: engine running at idle

Scope image 1

Pins to ground: 2U, 2V

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check resistance: Turn ignition off. Remove connector(s) from injector(s). Measure resistance between the two pins of the injector. Compare with specified resistance. Check supply voltage: Turn ignition off. Remove connector(s) from injector(s). Crank the engine and measure voltage between one connector terminal and the negative terminal of the battery. Check the second terminal, one of the two should equal battery voltage. If not check wiring and, if present, fuse(s) and relay or power supply control unit. Check connection to ECU: Turn ignition off. Remove connector(s) from injector(s) and ECU. Measure the resistance between one of the two connector terminals and the corresponding terminal in the ECU connector. Check the other terminal. One of the two should be < 1 ohm. If not check wiring. Check injector activation: Connect oscilloscope to one of the signal wire pin(s) of the ECU and ground. Start or crank the engine and compare to the scope image shown.


90. main relay

Function

Switches power to sensors, actuators and / or control unit.

Specifications

single normally opened relay.

Diagnosis

Check connector(s): Inspect the connector(s) and if necessary clean or fix them to make sure the connection is good. Check relay: Turn ignition off. Remove relay from relay box. Connect the input of the coil to battery voltage and the output of the coil to ground. The relay should click. If not replace relay. Check the switch of the relay. Measure the resistance between the input of the switch and the output(s). When coil connected the resistance should be < 1 ohm. When coil disconnected resistance should be infinite. If not replace relay. Check supply voltage: Turn ignition off. Remove relay from relay box. Turn ignition on. Connect a circuit tester between the input terminal of the coil or between the input terminal of the switch in the relay box and the negative terminal of the battery. The tester should light up. If not check wiring and, if present, fuse(s) and second relay. Check connection to ECU: Turn ignition off. Remove relay from relay box and remove connector from ECU. Measure the resistance between the output terminal(s) of the switch in the relay box and the corresponding terminal(s) in the ECU connector. It should be < 1 ohm. If not check wiring. Check connection to ground: Turn ignition off. Remove relay from relay box. Measure the resistance between the output terminal of the coil and thenegative battery terminal. It should be < 1 ohm. If not check wiring.


37. oxygen sensor

Function

The oxygen sensor is exposed to exhaust gas flow. It monitors the oxygen content of the exhaust gases. A low oxygen content (rich mixture) increases the output voltage of the sensor. In this way a constantly updated air/fuel ratiois returned to the control unit.

Specifications

output voltage: 200 - 850 mV waveform information: hot engine running at idle

Scope image 1

Pins to ground: 2N


Description Values Units Note 1/3Overhaul data - Cylinder block

MAZDA - B6 16V

General cylinder block data

Cylinder block height 221.5 mm

Cylinder bore

Bore

Standard 78.006 - 78.013 mm

1st Oversize 78.256 - 78.263 mm

2nd Oversize 78.506 - 78.513 mm

Cylinder bore ovality

Limit 0.019 mm

Taper

Limit 0.019 mm

Pistons

Piston diameter

Standard 77.954 - 77.974 mm

1st Oversize 78.211 - 78.217 mm

2nd Oversize 78.461 - 78.467 mm

Measuring point 18.1 mm below oil-scraper ringgroove

Piston rings

Height 1st compression ring 1.47 - 1.49 mm

1st Compression ring gap 0.15 - 0.30 mm

Limit 1.0 mm

2nd Compression ring gap 0.15 - 0.30 mm

Limit 1.0 mm

Oil-scraper ring gap 0.20 - 0.70 mm

Limit 1.0 mm

Side clearance 1st compression ring 0.030 - 0.065 mm

Limit 0.15 mm

Side clearance 2nd compression ring 0.030 - 0.065 mm

Limit 0.15 mm

Connecting rod

Center distance of big and small end bore 132.85 - 132.95 mm

Big end bore 48.000 - 48.016 mm

Big end bore width 21.838 - 21.890 mm

Big end bearing radial clearance 0.028 - 0.068 mm

Limit 0.10 mm

Big end, end play 0.110 - 0.262 mm

Data from secondary source; No manufacturer's information

© Copyright, Wessels + Mьller AG 23.03.2007


MAZDA - B6 16V

Limit 0.30 mm

Small end bore 19.943 - 19.961 mm

Radial play in small end 0.013 - 0.037 mm

Crankshaft

Max. crankshaft swing

Limit 0.04 mm

Number of bearings 5

Main journal diameter, standard 49.938 - 49.956 mm

Limit 49.904 mm

Main journal diameter, 1st Undersize 49.704 - 49.708 mm

Limit 49.652 mm

Main journal diameter, 2nd Undersize 49.454 - 49.458 mm

Limit 49.402 mm

Max. main journal taper

Limit 0.05 mm

Max. main journal ovality

Limit 0.05 mm

Main bearing clearance

Standard 0.018 - 0.036 mm

Limit 0.10 mm

Crankshaft end play 0.080 - 0.282 mm

Limit 0.30 mm

Crank-pin diameter

Standard 44.940 - 44.956 mm

Limit 44.908 mm

1st Undersize 44.690 - 44.706 mm

Limit 44.658 mm

2nd Undersize 44.440 - 44.456 mm

Limit 44.408 mm

3rd Undersize 44.190 - 44.206 mm

Limit 44.158 mm

Max. pin journal ovality

Limit 0.05 mm

Max. pin journal taper

Limit 0.05 mm

Big-end bearing radial clearance 0.028 - 0.068 mm




MAZDA - B6 16V

Thickness crankshaft thrust halfring


1st Oversize 2.625 - 2.675 mm

2nd Oversize 2.750 - 2.800 mm

Oil pump

Type trochoid

Clearance inside rotor - outside rotor 0.02 - 0.16 mm

Limit 0.20 mm

Clearance outside rotor - pump housing 0.09 - 0.18 mm

Limit 0.22 mm

Axial play outside rotor - pump housing 0.03 - 0.11 mm

Limit 0.14 mm



Description Values Units Note 1/6Overhaul data - Cylinder head

MAZDA - B6 16V

General cylinder head data

Cylinder head height

New 107.4 - 107.6 mm

Warpage cylinder head fitting face

Limit 0.15 mm

Max. grinding allowance 0.20 mm

Valves

Valve dish diameter (D)

Intake 29.4 - 29.6 mm

Outlet 23.4 - 23.6 mm

Valve length (L)




MAZDA - B6 16V

Intake new 103.84 mm

Limit 103.34 mm

Outlet new 104.94 mm

Limit 104.44 mm

Valve stem diameter (d) intake


Valve stem diameter (d) outlet





MAZDA - B6 16V

Valve seat angle

Intake 45 °

Outlet 45 °

Valve dish thickness (t)

Intake 0.9 mm

Outlet 1.0 mm

Valve springs

Length unladen

Intake 46.12 mm

Outlet 42.86 mm

Min. force at prescribed length 1




MAZDA - B6 16V

Intake 39 mm: 205 - 232 N

Outlet 38 mm: 133 - 151 N

Inclination(s)

Intake 1.61 mm

Outlet 1.50 mm

Valve guides




MAZDA - B6 16V

Fitting height

Intake A = 16.8 - 17.4 mm

Outlet A = 16.8 - 17.4 mm

Inner diameter, standard 6.01 - 6.03 mm

Clearance between valve stem and guide

Intake 0.025 - 0.060 mm

Limit 0.20 mm

Outlet 0.030 - 0.065 mm

Limit 0.20 mm

Valve seats

Seating angle (Я)

Intake 45 °

Outlet 45 °

Seating size (A)

Intake 0.8 - 1.4 mm

Outlet 0.8 - 1.4 mm

Rockers

Rocker-arm diameter 18.959 - 18.980 mm

Rocker-bore diameter 19.000 - 19.033 mm

Rocker radial play 0.020 - 0.074 mm

Limit 0.10 mm

Camshaft

Camshaft journal diameter, standard

1st Bearing 43.440 - 43.460 mm




MAZDA - B6 16V

2nd Bearing 43.425 - 43.450 mm

3rd Bearing 43.410 - 43.435 mm

4th Bearing 43.425 - 43.450 mm

5th Bearing 43.440 - 43.460 mm

Camshaft bearing radial clearance

1st Bearing 0.040 - 0.075 mm

2nd Bearing 0.035 - 0.080 mm

3rd Bearing 0.050 - 0.095 mm

4th Bearing 0.035 - 0.080 mm

5th Bearing 0.040 - 0.075 mm

Limit 0.15 mm

Camshaft end play 0.04 - 0.13 mm

Limit 0.15 mm

Max. camshaft swing

Limit 0.03 mm

Total camheight

Intake new 35.829 mm

Intake min. 35.629 mm

Outlet new 35.659 mm

Outlet min. 35.459 mm



Description Values Units Note 1/1Torque settings

MAZDA - B6 16V

Cylinder-head bolts

Stage 1 20 - 30 Nm

Stage 2 40 - 60 Nm

Stage 3 76 - 81 Nm

Main bearing cap 54 - 59 Nm

Connecting-rod bearing cap 50 - 54 Nm

Camshaft-bearing cap 7.8 - 11 Nm

Camshaft sprocket 49 - 61 Nm

Crankshaft sprocket 108 - 118 Nm

Valve cover 4.8 - 8.8 Nm

Flywheel 96 - 103 Nm

Drive plate 96 - 103 Nm

Intake manifold 19 - 25 Nm

Oil pump 19 - 25 Nm

Water pump 19 - 25 Nm

Oil-sump 7.8 - 11 Nm

Spark plug 15 - 23 Nm



1/1Lubricants and Fluids

MAZDA - 323 - 1.6i - B6

Engine

Motor oil API SG Below 0 °C SAE 5W-30

Motor oil API SG From -25 °C to 30 °C SAE 10W-30

Motor oil API SG Above -25 °C SAE 10W-40




Cooling system

Coolant All temperatures

Manual transmission (2WD)

Gear oil API GL-4 All temperatures SAE 75W-90


Manual transmission (4WD)



ATF Dexron II All temperatures

Automatic transmission


ATF M-III All temperatures

Transfer box

Gear oil API GL-5 Above -15 °C SAE 90

Gear oil API GL-5 Below -1 °C SAE 80W

Differential, rear (4WD)

Gear oil API GL-5 Above -15 °C SAE 90

Gear oil API GL-5 Below -1 °C SAE 80W

Power steering


ATF M-III All temperatures

Brakes system

Brake fluid DOT 3 All temperatures

Air conditioning

Refrigerant R134a

Compressor oil PAG, ISO 46


Capacities

MAZDA - 323 - 1.6i - B6

Item UnitsValues

Engine sump, incl. filter 3.4 (l)

Manual transmission

Gearbox refill 2.68 (l)

5.0Cooling system (l)


Timing

MAZDA - 323 - 1.6i - B6

General

NoteItem

Always check the timing marks before timing belt removal

Before disconnecting the battery cable, check the audio system anti-theft code

Removal

NoteItem

Disconnect the battery earth cable

Remove the lower engine cover

Remove the power steering pump belt

Remove the alternator belt

Remove the water pump pulley

Remove the crankshaft pulley

Remove the timing belt guide plates

Remove both timing-belt covers

Loosen the tensioner

Push the tensioner pulley away from the timing belt

Tighten the tensioner

Remove the timing belt

Remove the tensioner

Check the tensioner and idler pulleys, renew if necessary

64 mmCheck the free length of the spring

If out of specification, replace with a new one

Installation

NoteItem

Refit the tensioner

Refit the tensioner spring

Push the tensioner pulley away from the timing belt

19 - 25 NmTighten the tensioner

Check the timing marks

Fit the timing belt

Turn the engine 2 rotations clockwise


Loosen the tensioner

Tighten the tensioner



Measure the timing belt deflection

11 - 13 mm / 98 NThe tension is set at a deflection of:


Check the timing marks and tension again

10 NmRefit the timing belt covers

Refit the crankshaft pulley 15 Nm

Refit the water pump pulley

Fit the alternator belt

Refit the power steering pump belt

Refit the engine cover

Reconnect the battery earth cable

Torque settings

NoteItem

19 - 25 NmTensioner pulley:

157 - 166 NmCrankshaft pulley centre bolt

Crankshaft pulley: 15 Nm

10 NmTiming-belt covers:

10 NmWater-pump pulley bolts

Special tools

NoteItem

There are no special tools required


mazda 323 16v i b6

Documents

idle speed b

seconds light

test c60fastidle speed

cfastidle speed rpm2500

lambda change delta

negative terminal

positive battery terminal

oil temperature